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The three transfer modes in GMAW are globular, short-circuit, and spray. Today we are going to dive into the spray transfer mode on the ESAB Rebel 235.
In spray transfer MIG, the electrode metal is rapidly passed along the stable electric arc from the electrode to the workpiece, essentially eliminating spatter and resulting in a high-quality weld finish. As the current and voltage increase beyond the range of short circuit transfer the weld electrode metal transfer transitions from larger globules through small droplets to a vaporized stream at the highest energies. Since this vaporized spray transfer variation of the MIG weld process requires higher voltage and current than short circuit transfer, and as a result of the higher heat input and larger weld pool area (for a given weld electrode diameter), it is generally used only on workpieces of thicknesses above about 1/4" (6.4 mm).
Also, because of the large weld pool, it is often limited to flat and horizontal welding positions. It can also be used in overhead, but special techniques are required (as shown in earlier videos).
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Could u do a vid about flame straightening? Would be very interesting to me! I would also like to see Spray transfer on high amp maschines like 400-500amps with big wire sizes! Keep it up!
Hi Id Like a request for a Duplex 6g Tig /Stick.....and Tig with walk the Cup full pipe....I know you guys did a carbon steel but if you could do a Duplex with the test with regards to heat input or pitting test....even if the videos is in 2 or 3 parts id like to see one in the near future....Thanks.
Dear Bob i would be really gratefully i you could take the time and efford to make a video about :TIG welding aluminium thin (1mm) to thick (6mm) material + cold to hot + cold thick to hot thin .Thank you in advance you are a great source of knowledge for me that i have not access to training center .God bless you all , greetings from Greece.
Weld.com for people who do not have a welder and have not welded before they don't know the benefits of having a welder around the house. unfortunately the cheapest and easiest I know is the Harbor Freight Hunter and 110 volt flux core about 80 90 AMP welding machine for about $100 they can learn how to glue some Steel together. just wish I could show them how to work & stay in their puddle and make low amps work for them. can be a useful tool for around the house. just started being nice video for people who don't know. it's kind of like your phone compared to a computer. it's the convenience and portability of a hundred foot extension cord that makes it worth it.
Carbon Air Arc Cutting please.
Spray mig is done by using high wire speeds and higher than normal voltage. The arc happens long before the wire touches the base metal. The wire literally atomizes into fine droplets because of the high voltage. It normally uses an argon/oxygen mix of up to 5% oxygen. It's good for thick plate and high welding speeds.
Donald Parker thank you for explain. It is well appreciated. I just that new esab and does more than i know
Thank you for the explanation.
@@donparker8246 it also has little to no spatter and is super quiet
I like listening to guys like this explain these things that I have an interest in, he's obviously a skilled Tradesman, something that helped build our great country but we are sorely lacking today because of our short-sightedness everywhere
I'm an experience amature welder automotive work exhaust, frame, and sheet. I was working with my first stainless exhaust, stainless mig job, I was getting spray transfer at some points while doing 1/2" thick flanges and it looked amazing but I couldn't maintain it consistently and adjusted settings down.. it was .030, 309L wire, around 19- 20v , 200 -240 or so speed. Man no spark on stainless mig is so great, and the weld looked melted smooth like pipe solder.
Thank you so much for these videos. I love them. They help sooo much. I love that you show and casually talk through the process of finding the results your looking for. My FAVORITE thing about your videos is how transparent you all are with what your doing and why.
When I worked butler manufacturing I set machine .045 wire at 385 / 28.5 volts and was super smooth. Also, if you lay the gun on it side and pull towards you using small back and forth motion you’ll see it will have a much smoother weld.
What type of gas are you running?
@@chrisberrones9099 anything above 82% argon will work
Our Fab shop had all the machines setup for spray Mig with STD hardwire root pass then spray for full pen pressure vessel welds. It was really nice to walk through the shop with that setup. clean quiet and really beautiful welds.
Thanks for sharing
it's amazing to me that a .5v increase (2%) would make that much of a difference.
3:23 - short circuit MAG welding
7:00 - spray transfer MAG welding
The-Metal-Life globular
MAG welding? Which country are you from? We call it MIG here in NA. Metal/Inert Gas welding.
@@mikeford963 maybe you didnt think before? Metal active gas because CO2 in the mixture.
@@mrjodoe CO2 in welding is classed as an inert gas. Oxygen in welding is classed as an active gas. But thank you for making me think. I don't often get to use Oxygen as welding gas as most places use either straight CO2, or an Argon/CO2 blend.
@@mikeford963 co2 while welding is active. so welding class: F
I was just browsing. Stayed because of the good production value. Thanks.
This spraying transfer mode is nuts .... wow awesome !
35 years of SCM and TIG welding. Just left a welding test for a job at Caterpillar and screwed the pooch. It was Spray transfer (which I wasn't told in the interview by the employment agency) . min of 385 ipm around 28V and it felt so weird and much hotter than what I'm used to. They gave a Min of 6mm and 25% over with no more than 4mm of reinforcement. So easy You would think. My beads looked good, just not consistent. Had a difficult maintaining tolerance, I was always right at 6mm and 10mm seamed hard to get. It's all in My head I know and in fact was told to go home, practice with My own welder and come back. He liked My welds. Just first time Spraying and it felt so foreign that I gave up. I'm a puller (so is He) but found pushing was just as easy with spray at times ?
The 3rd pass you were in full spray mode but if you noticed your volts were up around 30. At work with .045 wire I don't start to get the spray effect until I'm pass 28 volts and around 390 wire speed. Just some info to pass on for anyone looking to spray arc.
Far more advanced than any welding I will ever need to do but very interesting and watchable...thx!
One of my favorite way for circle t-joint, the pass look like has made by automatically. Thanks for your job! Wish you luck!
Did you have a stroke recently?
Amazing video ! and I was waiting for it ! I've also noticed that there is almost no spatters at all when going to 30 volts. thank you guys for uploading.
We use this in work. I usually run 31 volts and 11.5 mps. Mostly 8 mm welds on half inch beams and plates
What industry? 8mm is pretty heavy duty on half inch plate
Geez when I anticipated an arc strike, I keep tryin to tip my helmet down.
lol
Haha I do the same sometimes
Im used to most imperial measurments but it is convenient that you included metric. Thanks a lot for that, shows you care about us heh
I run pulse spray everyday in production tracktor bucket plant called TAG Manufacturing i run select arc .052 430 wfs 30-32vlts , runs so smooth , can make a whole bead of glass , and yea no vertical spraying with that lol go ahead and try but i don't see it happening haha
Drake Wilcox Pulse for the win! Use it on my miller xmt and aluma feed.
Just took my weld test for TAG
Thank you for putting stuf in mm for the non imperials here
When spraying, fine tuning is much easier when adjusting voltage, always push.
Great machine , excellent teacher! Thank you.
The Spray Transfer method usually is best used for flat and horizontal. Pulsed you can run vertical and overhead, and short circuit can weld in all positions.
Thanks for also using metric. We usually use 0.6 0.8 0.9 1.0 1.2mm wire diameters.
1.6 also
My favourite setting is spray as you mentioned it has limits on positions you can weld with it. The heavier gauge the parent metal spray is better suited.
It can be set up to be extremely quiet and no spatter or sparks. The weld bead is uniform and no varying in throat thickness and size. I learned how to set it up welding automatically on pressure vessels used in truck breaking systems.
Sir 1/4 thikness plate what's voltage setting and wire speed .i hope u can answer me sir.for spray type mode mig welding
@@ranilioestreras I leaned the old school way.
You set your amps up higher than normal and adjust the wire speed until it goes quiet and makes a hissing sound.
The arc is very different and doesn’t short circuit.
This process also introduces more heat into the parent metal.
On a 250 Amp machine I set it to 24 volt, at first I have the wire speed on a high setting and adjust it down until I get the balance between short circuit transfer and spray transfer.
There’s a visible difference between spray transfer and short circuit.
On the spray setting the arc doesn’t break away with the metal deposit.
The arc actually looks like it is stable like that of TIG welding the deposit rate is very fast.
I would not recommend using it on 1/4” - 6 mm plate.
I use it on front loader buckets to weld wear plates.
Not sure what the terms used today most MIG welding is done with an arc force setting of 20.
Hi Bob we always use 92/8 gas big Fab shops in Kansas building some of the craziest stuff you can imagine I seen one comment about 0 45 on a larger machine we would run on dual stage wire feeders 300 inches on the low side in between 4 and 6 on the high side depending on what we welded the bigger machines that we worked with we're 4042 volt
Fantastic learning material for my classes 👍
Had to weld some 1/2" 4140 in a rush, slapped a spool of 0.035" ER80S-D2 into my aluminum spoolgun on the lincoln MP350 with straight argon and cranked it up until it sprayed like this. Worked pretty good for running what was available
.....8:20.....looks about right, sounds about right......! I did a lot of this with .045 on my old Millermatic 200 .....
What a cool process, need to try that one day.
Spray transfer is so satisfying :)
Another awesome and very informative video. Thanks Bob!!
That is pretty cool. Now I really want to give this a try on my everlast welder.
damn this is fabulous it woudl be very interesting if you cut and etch a piece
That machine sure is putting out a lot of amps for a "250 amp" machine! impressive.
Thank you for your induction into spray transfer method
it's always awesome and very informative to watch you work.
+1 on the duplex pipe.
If anyone is wondering what happens when you weld spray in the vertical or even slightly uphill position it just piles up on itself it’s too hot and too liquidy, you have to weld it in the horizontal or slightly downhill position, slightly downhill is probably best, I love spray but as you can see in the vid it’s a bitch to find that sweet spot
I have seen people trying to weld vertical down with Spray. It just end up as a large lump of metal at the bottom.
Yep it can be a bitch to find the sweet spot.
My favorite is when all you hear is a hissing sound like as if you’re are using TIG.
I learnt this method welding pressure tanks for truck breaking systems.
It is great because you don’t have the crackling sound, you might get a pop every now and then.
It definitely is one technique that one should master because it is high productivity and deposit rates.
Some new machines don’t allow individuals to adjust wire speed while welding.
@@21gioni that is absolutely incorrect the largest Foundry in the Free World is automated and I'll guarantee you every frame that carrys every casting had the corner spray arc down hill
@@okiedoke6373 There is a setting that is close to a spray arc that is used to weld vertical down, lots of people think that’s a spray arc setting but it is not.
There is a possibility that a special gas is being used that assists with solidifying the weld pool.
Hydrogen mixtures can do this but I haven’t tried spray arc with hydrogen gas mixtures.
What gas are you using?
@@21gioni no you don't use no you don't use hydrogen in the hell is wrong with you I've been welding for 35 years what in the hell are you talking about special gas to run downhill with spray you just run it straight down yeah just so you know it's the hydrogen you're trying to keep out of the weld
Another excellent video Bob thank you.
Thanks Bob I really enjoy your videos !!!
Hey Bob, I'm just wondering what spray transfer is used for primarily.Thanks.
Are you cleaning off the glass before the new bead?
First off- Great job👍 next is it’s nice you show spray arch with 95/5 oxygen but a lot of us don’t have this option? The suppliers think they know what’s best so our options are limited.
Vertical spray works great try it l use all the time
We run 98-2 on our spray transfer welds very great!
I tried convincing a former employer of mine to let us welders set our machines instead of forcing us to use presets.
Instead, they ignored me, and we would spend hours a week removing spatter from logging trailers, including each pocket where the pickets go.
None of the settings we used were very good at all.
Some people just don't know what is good for them.
Awesome, Thanks for the video. Never seen that done.
Thanks, Bob!
I just bought the rebel 235 and noticed that the sMIG function on .045 capped out at 3/16" material thickness and was very surprised to see that. The regular mig unction will allow much higer settings. I went searching for videos on this topic and ran across yours that verified this is the way the machine is set up. Why would ESAB limit the sMIG to 250ipm with .045 wire? With .035 wire sMIG will go all the way to 3/8' thick.
Also, how did the machine go over its rated 250 Amps and sustain it at 290 amps?
Appreciate your videos , keep "pulling the trigger" for us
Friday i played around a little with spray, normally im welding 1/4" up to 1-1/2 steel building agrictural equipment, i normally run at 30 volts and 360 inches a minute with .045, using a miller cp302 and 60 series miller wire feeder, 90/10 gas, i wanted a deeper weld for the thicker material, i was able to run about 400 inches a minute at 32 volts and was fine, i tried 35 volts and 500 inches a minute and also 40 volts and 600 inches a minute with a #13 shade and at 35 and 40 volts it was so hot i wasnt even able to see what i was welding, got good penetration on 3/4" plate but was extremely difficult to define the weld joint and the puddle, im gonna stick 30 to 32 volts, was fun to try it out though, i tried spray at 27 and 28 volts and was not able to get into spray,for some reason on this machine i wasnt able to reach spray till around 29 to 30 volts
What are the settings for spray and does it work on flux core , stainless steel or any other process???
Not to sound stupid but ive never used pulse mig or spray transfer ive done duel shield flux core in 1/16 as well as .045 ive done 3/16 7024 drag rod as well as 5/32 drag rod ive done many forms of welding just never used spray transfer or pulse mig. Whats the purpose like what would it be used for...help?
Nice welds. I want to see that overhead spray, that would be awesome.
I'mNotFucking HereRightNow Agreed, could make for an interesting video.
I'd like to see some videos with pulse spray (any position). I'm thinking about getting an everlast mig welder that can pulse.
I read that it's best to have a gas mixture with at least 80% argon, what do you think?
yep. I would rather spray overhead, it keeps the spatter off me and out of my nozzle.
good tips. I'm learning some things
It sounds decent, looks ok, but how foes it fair? Xray? Bend? Please test some
Would ther be a way to mix Helium ,and Argon to spray weld?
I'm thinking about getting an Everlast welder that supports pulse mig. Would pulsing while spraying help with welding out of position?
Nice edit during the intro
...many newer types of gas mixes and welder functions, since I had a shop in 1981-85.....I bought a new MillerMatic 200 in 1981....built lots of woodstoves/heaters...guy at the welding store says..."First thing you should do is install a Tweco #400 Mig gun, if you're going to be doing a LOT of steel plate".......and try this gas mix...90% Argon, 8% C02. 2% Oxygen.... Radnor calls this 'Stargon'.....
I've found that like most recommendations...minimum 90% Argon for spray.....but 100% won't work either....need a bit of ox in there....98/2...Argon Oxygen...but the tri-mix worked well for me...I ran about 300 of those #33 rolls of Mig wire.....in 4 years...sometimes used a roll in 2 days.... .035 and .045....with .035...need a good 175 amps minimum for spray....a little more for .045"....Millermatic has been 100% adequate for this, I've even run a few rolls of .045 Fluxcore....both Innershield and dual-shield....
When we spray we are usually 28 to 29 volts and 465 to 480 ipm on the wire speed. thats with 035 wire which we use most of the time. the .045 wire we run at 29 volts 400 IPM.
Should've ran 525-550 and 27. Would've laid a nice bead with great penetration. And I run Vert downs with those same settings it's pretty easy, just don't manipulate on ⅛ or 3/16 material and go slightly faster.
Lincoln MC6 045 with 90/10 gas is good spray transfer
Can the 215ic spray arc transfer on a similar level to the 235ic?
I will be working mainly on 3mm wall, box section (SHS, RHS) but also the odd 10 / 12mm gusset plate work on-site
Cheers
Think you can run some out of position 3G and 4G gas-shielded FCAW?
Hope you see this. Just got a brand new Emp 235 Ic. Will not go over 26volts
Can you please do a video with Yes welder pro200
Your camera shots are awesome!
It can run 290A on air cooling? That is truly impressive!
Especially since it's supposed to be a 250 amp machine as per Esab!
hi I am pressure welder from Canada .. I have just got a job spooling x ray quality pipe 2" 6" up to 20 " . the fitters suck I like a 1/4 gap no land this hardly ever happens..im running around 19 and 250 inches etc I run stick not mig . Would u have any ideas how to make my life easier ? Stick I got it covered but almost never ran a mig have had 6 repairs in 150 welds more fluke than skill..thanks great vids!
28 and 550 works pretty well too
Hi!
Can I weld spray transfer with 82%argon and 18% co2?
Thank you for the videos Bob, I always enjoy watching your welding projects. On your last spray arc pass you had the split screen and I could see the ESAB 235ic ( I own the Esab 215ic) volts start at 28.5 & go as high as 30.0 at the very end of your weld. Question- in manual mig mode does the machine vary the volts because in S-mig I know it does? I really like my Esab 215 a lot and if I ever need to spray arc I use my Esab 250 Migmaster which is great transformer based machine. That's part of the reason I went with the 215ic instead of the 235ic. I have my Big Blue and Tan machines but they tend to be Garage furniture for the past few years lol.
Thanks, Lou
are you in the uk/eu? because there is actually two versions of the 235 and 215
I love spray using 1/16 wire 98 argon 2% co2 lay a nice weld
hello bob greetings from colombia, my question: can I apply mig welding in the form of a spray transfer in a vertical position up to 1/2 "thick, 3/4" 3/8 "with bevel and intertice plates? I hope your answer bob many Thank you .
Is there a fan I can install in my helmet , im looking for something like a small aircondition unit
Air-con units just move heat from one spot to another, so a tiny one wouldn't have much if any appreciable difference. They do make "cooling" systems, but it's mostly just relying on a fan / blower unit that pulls air from behind you and feeds it through a hose into your hood. That air will naturally be a bit cooler than the air that normally wafts in from a foot or two away from the arc, and it can help with fume a bit, assuming you're not in an enclosed space where the air doesn't circulate much.
Are that it more options than short circuit and spray transfer.
Great video Bob.
at work.. when we are working on contract jobs we run .035 LA100 wire with 98/2 mixture.. around 26V and 460 WFS.. when not on these contracts we run 75/25 and .035 L56 wire. do you have any recommended setting? I found decent results from 27.5V and 430 - 460WFS. in the video you had same voltage and less WFS with 95/5 but for .045 dia
tnx for your informative video, what mig settings should be set on our welder machine for 5mm flat Y-butt (3mm gap) weld of stainless steel in order to achieve spray arc transfer mode?
Ran this at a job for a little over a year.. on thin metal I might add.. better move quick or your gonna burn through. Lol we used 90/10 argon/co2 at around 28-32v
If it's digging out the Base metal in front of the molten pool is it too Hot?
I am looking at a chinese welder but it only does 24v and 270 amps. Can I still spay transfer without 25 volts?
Not an expert but, depends on wire diameter and type. .023 wire sure.. maybe up to .030 but not consitently.
At work I weld quarter inch plate 2 quarter inch thick Square tube in a j Groove horizontally we use . 045 C20 gas I have a hard time avoiding undercut any suggestions
Hi have you ever used select wire to mig with
Can i run er70s-2 steel wire with 95/5 mix? Currently running on argon/co2 (c-25)..
At the 10:00 mark you mentioned using spray mig in the overhead postition. I was wondering what your settings on your machine were, travel speed, and mig gun angle. Is there any way you could make a video of this I would love to see how this is done.
Is it possible to spray aluminium overhead?
Do you suppose spray-arc trasfer using the MIG process could be used instead of flame spray to build up a layer of material on round stock being turned in a lathe? What would make one process preferred over the other?
The thickness you can build up with flame spraying is a lot less.
So for a slightly worn shaft you would flame spray,as the MIG wil deposit to much material (so more time spent machining) and for a very worn shaft the flame spraying takes way too long.
So:
Slightly worn = flame spraying
Very worn = Mig welding.
how is it putting out 290a when specs say 250 max?
Great video
I also meant to ask if you ran the .045 wire in the conduit installed in the spray master 200 mig gun as delivered. It is supposed to be an .030/.035 conduit I believe but the manual supplied seems to imply you can run .045 in it as is.
I see on your machine when you were setting it up on the digital panel it said mig/mag what's the difference? Is one spray and the other short circuit? Thanks for making these videos I have learned a ton form you.
Bob can you explain why a line forms in the middle of the bead on a spray transfer? In short circuit I don't see that same line forming.
Freeze line. Google it. There are articles out there that can explain it better than I can.
Esab rep says the emp 235 won't do .045 spray. It's designed for .035 spray.
I love the pulse spray on Lincoln 350 mp.
I have the 350MP set up for aluminum and use an S500/Powerfeed 84 or the Miller Continuum set up for mild and stainless at work. The Miller is more finicky and less forgiving with the settings but if you dial it in right it seems to be a little better. The Powerfeed is just the 350MP on steroids. Also, contrary to what Bob says, I'll do vertical (uphill or downhill) with spray settings any time, but if I have a bigger gap to bridge on (or even in general with) thinner material, I switch to short circuit.
очень много использую такой режим сварки , мне нравится). каждый день пользуюсь ! часто свариваю толстый металл , от 6 миллиметров до 20 миллиметров !!!
возникают трудности с перегревом сварочного аппарата!( модель Kemppi wfx 300 p
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